Summary
Overview
Work History
Education
Skills
Timeline
Generic

Sameer Kataria

Solan

Summary

A leadership position with an organization of repute to utilize acquired skills & knowledge contributing to sustainable growth and profitability by fostering a “Best in class” work culture. EXECUTIVE SYNOPSIS Mechanical Engineer, Certified Lean Practitioner, Business Excellence Master Black Belt and Six Sigma Black Belt with over 22 years of rich experience with leading manufacturing organizations. Experience spans Manufacturing Operations, Manufacturing engineering, Operational Excellence, Planning, Maintenance, New product launches, Product transfer, Capital equipment procurement, New assembly line setup, Brown field projects. Proficient in deploying Shop floor production control systems based on Daily work management principles. Assembly Process improvement thru’ implementation of Built in Quality Concept. Capacity release thru’ systemic losses reduction thru’ focused improvements implementation. Conversant with Production Preparation Process (3P) Methodology for Plant transformation. Deft in Process cost optimization including consumable and packaging cost optimization. Deft in deploying Lean Manufacturing, Six Sigma (DMAIC), TPM, VSM, QC Circles, Kaizen, SMED, 5S,3M and ZQC(Poka-yoke). Well versed in managing manufacturing processes in diverse industries– delivering on all key performance metrics. Capable of deploying Industrial Engineering tools like work & time study, plant layout and line balancing.

Overview

24
24
years of professional experience

Work History

Manufacturing Engineering & Plant Engineering Leader

Ingersoll Rand India Limited
Ahmedabad , Gujarat
04.2019 - 03.2020

Plant Director and Director

JOHNSON CONTROLS PRICOL PVT LTD
Pune
01.2013 - 10.2013
  • AME & Strategic Initiatives (Dotted); Team- 11 (2 Managers, 2 Deputy Managers, 4 Engineers, 1 Lean technician and 2 Maintenance technicians)
  • KPI’s- Lost Time Incident rate, Total recordable Incident rate, BBS Audit Score, Takt Time Adherence, Past Due, Inventory Turns, Earned Hours Efficiency, ICQ PPM, Warranty PPM, LOH Savings, Capex Utilization, NPD Projects Gate Adherence, Uptime, MTBF, MTTR, PM Adherence and Energy Savings
  • Job Profile
  • Managing and improvement of the Plant capacity, Manpower planning & Hourly production rates (routing hours)
  • Improving Earned hour efficiency with loss reduction thru’ focused improvements
  • Process improvements, de-bottlenecking and value stream transformation projects
  • Deploying robust preventive maintenance program and autonomous maintenance program
  • Driving down indirect spend in shop-floor consumables and other conversion costs
  • Capital Equipment Procurement for Naroda location
  • Deploying returnable and reusable packaging from suppliers for reducing environmental impact
  • Ergonomics study and implementing relevant improvements along with EHS
  • In-process Quality performance and process risk reduction and mitigation planning
  • Preparation of Plant Capex budget in-line with plans and strategic initiatives
  • Process control documentation like PFC, PFMEA, Control Plan and Visual Standard work
  • Manufacturing related Gate deliverables for all NPD and VA/VE/In-sourcing projects
  • Achievements
  • Successful completion of Naroda Brown field Plant transformation project
  • Generated soft savings of 500 KUSD, Space savings of 30 % and head count reduction of 25
  • Won the President Award awarded by SBU President in 2020 for highest COPQ reduction among all global CTS locations
  • Deployed DC tools in Small Recip
  • Assembly Shop for better torque control and over 35 percent warranty reduction
  • Deployed state of art paint system in Reciprocating Bare paint shop for reducing paint consumption by over 20%
  • Successful commissioning and handover of Equipment worth 3000 KUSD (20 Crores INR) Including Lab view based Test cells, Cranes, Air pallets, leak testing equipment, spray paint booth, Narrow Aisle truck, High rise racks, BOPT, Tow tractor and Fork lift trucks, Torque tools, Assembly work stations, fixtures and kitting trollies
  • Generated LOH Hard Savings of 270 KUSD by working on 2 key projects of packing improvement in compressor lines
  • Successfully deployed Braze Excellence global standard work on Dryer lines
  • Successfully eliminated 40 hammers from compressor assembly lines by deploying alternative tooling
  • Successfully led clean NPD launches of Chakra (Rotary), 3CII-I (Centrifugal),Trishul and Triveni (Dryers)
  • 50:50 JV between Johnson Controls Inc USA & Pricol Ltd
  • India Products: Dashboard instruments.

Sr. Manager

Won 2
01.2013 - 10.2013
  • Reported to: Technical Operations Head; Team: 3
  • KPI’s- Cost Savings actual and pipeline, Conversion Cost/Equivalent unit, Machine Utilization (MU) and OEE
  • Job Profile
  • Facilitate execution of continuous improvement projects in all departments of the plant
  • Engage with CI Managers of other automotive electronics plants to share and implement operational best business practices
  • Led implementation of TPM (5 pillars – JH, KK, PM, QM & SHE) for BAL Product lines according to BAL guidelines
  • Led cross functional teams in systematically identifying & eliminating 16 losses in the SMD line
  • Monitor Conversion Cost per Equivalent Quantity Units (EQU’s) to identify cost reduction opportunities
  • Drive PCB in-sourcing projects with ME team for reducing Purchase burden on Plant
  • Achievements
  • Led efforts at JCP Pune & Pricol Plant 5 and won the Prestigious BAL TPM Award
  • Drove continuous improvement projects with cumulative saving opportunities of INR 23.0 million
  • Closed CI Projects worth 7.0 million in FY 2013-14
  • Improved machine utilization of the SMD line by 5% in 3 months.

Deputy Manager

10.2010 - 11.2011

VISTEON CLIMATE SYSTEMS INDIA LTD
05.2007 - 11.2011
  • JV between a Fortune 500 company Visteon Corporation USA & Maruti Suzuki Ltd
  • Largest manufacturer of aluminium radiators & engine cooling modules in India with a capacity of 1 million units per year.

Group Leader

01.2004 - 06.2005

Senior Engineer

MINDA HUF LTD
02.2003 - 06.2005

Engineer

06.2001 - 02.2003

PRICOL LTD
Gurgaon
01.1999 - 02.2003

Practice Head- Operational Excellence

Samvardhana Motherson Group
Noida, Uttar Pradesh
07.2022 - Current

SAMVARDHANA MOTHERSON HEALTH SOLUTION LTD
11.2020 - Current
  • Samvardhana Motherson Health Solution Limited is an Indian company, part of Samvardhana Motherson group, leading automotive systems provider to leading OEM’s worldwide.

Site Leader

Samvardhana Motherson Group
Baddi and Paonta Sahib, Himachal Pradesh
01.2021 - 07.2022

Team Leader

Samvardhana Motherson Group
Paonta Sahib , Himachal Pradesh
11.2020 - 01.2021

Manufacturing Engineering Leader

04.2014 - 03.2019

Manager

11.2013 - 04.2014

SCHNEIDER ELECTRIC INDIA PVT LTD
Chennai
11.2011 - 12.2012
  • Wholly owned subsidiary of Schneider Electric France Products: Miniature circuit breakers and Residual current circuit breakers for final low voltage applications
  • Manager – Business Process Excellence (Lean Six Sigma)
  • Reported to: Plant Head and Matrix Reporting to GM-Supply Chain Excellence; Team: 3
  • KPI’s- Cost Savings, RCA’s Closed, No
  • Of Kaizen Blitz completed, 5S Score, SPS Audit Score and COPQ
  • Job Profile
  • Coordinated execution of Six Sigma, Lean Kaizen and Just do it Projects in the plant
  • Driven systematic problem solving by leading root cause analysis (RCA) sessions for various product lines
  • Supervised the deployment of Schneider Production System (SPS) and assured compliance through audits
  • Conducted training programs on continuous improvement tools like Lean, Six Sigma, Kaizen and SPS
  • Achievements
  • Mentored 28 continuous improvement (CI) projects in Production, Quality, Methods, Maintenance & Supply Chain departments in 2012 delivering savings of INR 10.54 million
  • Organized BPE workshops for the management team and identified 80+ improvement opportunities
  • Chennai plant won the 2nd prize in the annual Kaizen Conference at APC Bangalore

Deputy Manager

09.2009 - 09.2010

Assistant Manager

05.2007 - 08.2009
  • Reported to: GM-Manufacturing & Facilities Team: 72 – 4 Engineers, 8 Supervisors & 60 Operators
  • KPI’s- LTIR, TRIR, Built to Schedule, Units/Man hour, First Pass Yield rate, OEE, Delivery Adherence, Dock Audit PPM, In-process PPM, Customer PPM, Changeover time, Process Capability Indices, MTBF, MTTR, Uptime etc
  • Job Profile
  • Supervised Production, New launches, Manufacturing Engineering, Tool room & Facilities
  • Coordinated development of tooling & fixtures, setting up new lines, manpower allocation and tracked projects ensuring smooth launch of new models
  • Managed operation & maintenance of the assembly lines delivering targeted overall equipment effectiveness (OEE)
  • Led the deployment of value stream mapping (VSM) in all departments and achieved final state map (FSM) objectives
  • Deployed Built in Quality in manufacturing lines and Quality Circles & 5S across the organization
  • Achievements
  • Launched and ramped up production of several new models of engine cooling modules for Maruti Suzuki – YV4 petrol & diesel, YC5, YR9, YG4, YG4CD including CAC for YV4 Diesel
  • Conducted work study, line balancing, deployed standardized work & process improvements
  • Increased units per man-hour in crimp line by 15% and ECM line by 30%
  • Implemented a Lean project for achieving single piece flow between radiator line and ECM line saving INR 3.5 million per year
  • Completed a Green Belt project improving first time through (FTT)from 97% to 98.5% in the crimp line with annual cost savings of INR 0.35 million
  • Reduced Die changeover time in the crimp line from 15 minutes to 12.5 minutes through a Lean project and saved costs of INR 0.2 million per year
  • Conceptualized and implemented 12 Poka-yoke (error proofing) measures in the new YR9 ECM line
  • Developed suppliers for ELV compliant labels & markers which saved costs of INR 0.8 million
  • Facilitated smooth launch of new models with line setups achieving over 80% Poka-yoke coverage
  • Won 2 nomination certificates for the prestigious “Leading the Way” award given by CEO of Visteon Corp
  • Contributed towards winning Shingo Silver Medallion to Visteon Climate Systems India Ltd
  • Bhiwadi Plant.

BARCO ELECTRONIC SYSTEMS LTD
07.2005 - 05.2007

Kaizen Coordinator

02.2003 - 12.2003

Manufacturing Engineering

G.E.T
06.1999 - 05.2001

Education

MBA - undefined

Deakin Business School Australia

PGDBA - Operations Management

DLP - undefined

Welingkar Institute

BE - Mechanical Engineering

GZS College of Engineering & Technology Bathinda, Punjab Technical University

Diploma - Industrial & Production Engineering, Polytechnic

Govt, Board of Technical Education

Lean Six Sigma Master Black Belt, TUV SUD India - undefined

Advanced Lean Practitioner (Mentor), BMGI India - undefined

IATF 16949 Lead Implementer Course, Sub mastery - undefined

Trained ISO - undefined

Intertek USA, 2020 Lean Leader Development Program, Ingersoll Rand University - undefined

Lean Six Sigma Black Belt, The Pyzdek - undefined

Certified Lean Expert, Uni-world Consulting, USA - undefined

Skills

Passport Noundefined

Timeline

Practice Head- Operational Excellence

Samvardhana Motherson Group
07.2022 - Current

Site Leader

Samvardhana Motherson Group
01.2021 - 07.2022

SAMVARDHANA MOTHERSON HEALTH SOLUTION LTD
11.2020 - Current

Team Leader

Samvardhana Motherson Group
11.2020 - 01.2021

Manufacturing Engineering & Plant Engineering Leader

Ingersoll Rand India Limited
04.2019 - 03.2020

Manufacturing Engineering Leader

04.2014 - 03.2019

Manager

11.2013 - 04.2014

Plant Director and Director

JOHNSON CONTROLS PRICOL PVT LTD
01.2013 - 10.2013

Sr. Manager

Won 2
01.2013 - 10.2013

SCHNEIDER ELECTRIC INDIA PVT LTD
11.2011 - 12.2012

Deputy Manager

10.2010 - 11.2011

Deputy Manager

09.2009 - 09.2010

VISTEON CLIMATE SYSTEMS INDIA LTD
05.2007 - 11.2011

Assistant Manager

05.2007 - 08.2009

BARCO ELECTRONIC SYSTEMS LTD
07.2005 - 05.2007

Group Leader

01.2004 - 06.2005

Senior Engineer

MINDA HUF LTD
02.2003 - 06.2005

Kaizen Coordinator

02.2003 - 12.2003

Engineer

06.2001 - 02.2003

Manufacturing Engineering

G.E.T
06.1999 - 05.2001

PRICOL LTD
01.1999 - 02.2003

MBA - undefined

Deakin Business School Australia

PGDBA - Operations Management

DLP - undefined

Welingkar Institute

BE - Mechanical Engineering

GZS College of Engineering & Technology Bathinda, Punjab Technical University

Diploma - Industrial & Production Engineering, Polytechnic

Govt, Board of Technical Education

Lean Six Sigma Master Black Belt, TUV SUD India - undefined

Advanced Lean Practitioner (Mentor), BMGI India - undefined

IATF 16949 Lead Implementer Course, Sub mastery - undefined

Trained ISO - undefined

Intertek USA, 2020 Lean Leader Development Program, Ingersoll Rand University - undefined

Lean Six Sigma Black Belt, The Pyzdek - undefined

Certified Lean Expert, Uni-world Consulting, USA - undefined

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Sameer Kataria